Remote monitoring for fluid applicator system

ABSTRACT

In one embodiment, a remote monitoring system for a fluid applicator system is disclosed. The fluid applicator system is disposed to heat and pump spray fluid, and to transmit reports including sensed temperatures, pressures, and other operational parameters of the fluid applicator system via a wireless network. The remote monitoring system comprises a data storage server, and an end user interface. The data storage server is configured to receive and archive the reports. The end user interface is configured to provide a graphical user interface based on the reports. The graphical user interface illustrates a status of the fluid handling system, sensed and commanded temperatures of the fluid handling system, sensed and commanded pressures of the fluid handling system, and usage statistics of the fluid handling system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/145,791, filed Jan. 11, 2021, which is a continuation of U.S.application Ser. No. 15/910,272, filed Mar. 2, 2018, which is acontinuation U.S. application Ser. No. 14/766,712, filed Aug. 7, 2015,which claims the benefit of PCT Application No. PCT/US2014/015698, filedFeb. 11, 2014, which claims the benefit of U.S. Provisional ApplicationNo. 61/763,352, filed Feb. 11, 2013, the disclosures of which are herebyincorporated by reference in their entirety

BACKGROUND

The present invention relates generally to fluid applicator systems,such as those used to apply spray coatings, polyurethane foam, and thelike. More particularly, this invention relates to a monitoring systemand user interface for remotely gathering and archiving real-time andhistorical data about a plurality of such fluid applicator systems.

Fluid applicators are used to apply a variety of materials, from hotmelt glue to polyurethane coatings. Fluid applicators commonly includeboth heaters that heat fluids to specified temperatures (e.g. to achievetarget viscosities), and motor-driven pumps that pressurize fluids tospecified pressures for spraying and/or recirculation. Some fluidapplicators, particularly those used to apply polyurea, polyurethane,and similar materials, have separately heated and pumped “A-side” and“B-side” fluid systems that carry different fluids that are onlycombined when sprayed or otherwise applied. Many fluid applicators havelocal operator interfaces (LOIs) that provide fluid system operatorswith substantially real-time readouts of fluid temperatures andpressures, and allow operators to alter target temperatures andpressures by inputting temperature or pressure setpoints.

Fluid applicators are often mobile, and are sometimes installed onwheeled or otherwise mobile platforms or carts that can be pushed ordragged into work locations by hand, as needed. In industrial andconstruction applications for which multiple fluid applicators may beneeded at different, changing, and farflung locations, fluid applicatorsare often brought to work locations in dedicated vehicles.

SUMMARY

In one embodiment, a remote monitoring system comprises a fluid handlingsystem and a communications module. The fluid handling system comprisesa fluid delivery subsystem, at least one pressure sensor, at least onetemperature sensor, and a fluid handling system processor. The fluiddelivery subsystem is configured to pump and heat a fluid. Thetemperature and pressure sensors are disposed on the fluid deliverysubsystem to sense temperatures and pressures of the fluid,respectively. The fluid handling system processor is configured toproduce duty data and commanded pressures and temperatures for the fluiddelivery subsystem, and to receive the sensed pressures andtemperatures. The communications module is attached to the fluidhandling system, and comprises a communications module processor and atransceiver. The communications module processor is configured toretrieve a first data set comprising the duty data, the commandedpressures and temperatures, and the sensed pressures and temperatures,and to produce a second data set that includes the first data set. Thetransceiver is disposed to transmit the second data set via acommunication network to an end user-accessible data storage server.

In another embodiment, a remote monitoring system for a fluid applicatorsystem is disclosed. The fluid applicator system is disposed to heat andpump spray fluid, and to transmit reports including sensed temperatures,pressures, and other operational parameters of the fluid applicatorsystem via a wireless network. The remote monitoring system comprises adata storage server, and an end user interface. The data storage serveris configured to receive and archive the reports. The end user interfaceis configured to provide a graphical user interface based on thereports. The graphical user interface illustrates a status of the fluidhandling system, sensed and commanded temperatures of the fluid handlingsystem, sensed and commanded pressures of the fluid handling system, andusage statistics of the fluid handling system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial schematic diagram of an embodiment of a remotemonitoring system for a fluid handling system.

FIG. 2 is a schematic block diagram of an embodiment of a communicationnetwork of the remote monitoring system of FIG. 1.

FIG. 3 is an illustrative view of a graphical user interface for an enduser interface of the remote monitoring system.

FIG. 4 is a method flowchart illustrating one embodiment of a method ofoperation of the remote monitoring system of FIGS. 1 and 2.

DETAILED DESCRIPTION

FIG. 1 is a pictorial schematic diagram illustrating one embodiment ofremote monitoring system 10, which comprises fluid handling system 12,communications module 14, communications network 16, data storage server18, and end user interface (EUI) 20. The illustrated embodiment is shownmerely by way of example, and not limitation.

Fluid handling system 12 is a fluid system such as a polyurethanesprayer or hot melt sprayer. Fluid handling system 12 comprises fluidhookups 22, pump module 24, heater module 26, and local operatorinterface (LOI) 28, as well as further logic components described below,with respect to FIG. 2. Pump module 24 is disposed to draw fluid fromreservoirs (not shown) attached to fluid hookups 22, and to pressurizefluid to desired setpoint pressures. Pump module 24 can, for example,comprise a motorized pump or set of pumps driven by one or moreelectric, hydraulic, or pneumatic motors. Heater module 26 is configuredto heat fluid pressurized by pump module 24 to desired setpointtemperatures. Heater module 26 can, for example, comprise a fluidchannel or set of channels outfitted with electrically resistive orchemical heating elements. Pump module 24 and heater module 26 togethermake up a fluid delivery subsystem that brings fluids to specifiedpressures and temperatures (and thereby viscosities) suitable forspraying or other application to a work surface. In the illustratedembodiment, fluid handling system 12 is a two-side fluid system with A-and B-sides dedicated to different fluids that are mixed only whensprayed. In other embodiments, however, fluid handling system 12 cancomprise any number of separate fluid lines, or a single fluid line.During use, fluid from heater module 26 and pump module 24 can, by wayof example, be pumped through a hose or pipe to a sprayer or applicator(not shown).

LOI 28 is an interface device that enables a local operator to read offsubstantially real-time sensed values of fluid temperature and pressure,and specify setpoint temperatures and pressures to act as commandedvalues governing the operation of pump module 24 and heater module 26.Where pump module 24 and heater module 26 comprise multiple isolatedfluid lines for separate fluids, LOI 28 allows users to select differentcommanded temperatures and pressures for each fluid line.

Communications module 14 is a remote communication device attached tofluid handling system 12. Fluid handling system 12 and communicationsmodule 14 together comprise a fluid applicator system that can betransported (e.g. via truck, or by cart) to an appropriate worklocation. Although communications module 14 is depicted as a separatedevice connected to fluid handling system 12, communications module 14can be either a separate device affixed to fluid handling system 12, oran integrated component of fluid handling system 12, as desired forparticular applications. Communications module 14 retrieves operatingparameter data from fluid handling system 12, gathers additionallocation-specific data, and transmits reports including both of thesedata sets, as described in greater detail below with respect to FIGS. 2and 4. Communication module 14 allows local information about the fluidapplicator system, and particularly about fluid handling system 12, tobe accessed, aggregated, and archived at remote locations.

Communications module 14 transmits reports (either periodically, or ondemand) through communications network 16 to data storage server 18 viacommunications network 16. In some embodiments, communications module 14regularly assembles and transmits reports based at least in part on apre-set schedule. In further embodiments, communications module 14 cantransmit reports based on the content of process data received fromfluid handling system 12, e.g. conditionally transmitting some reportsin the event of unexpected sensor readings or event/error codes.Communications network 16 is illustrated as a cloud, but can be any datadistribution network. In particular, communications network 16 caninclude a cellular or other wireless network, either a dedicated networkpurposed specifically for use with remote monitoring system 10, or ageneral purpose network shared with other applications. Data storageserver 18 can, for example, be a single storage device or storage stack,or an array of distributed devices.

Data storage server 18 archives reports from communications module 14,either indefinitely or for a predetermined time (e.g. for the last week,or the last six months), so that history data is accessible at EUI 20.EUI 20 can be dedicated hardware terminal designed for use with remotemonitoring system 10, a general purpose computing device with suitablememory and processor capabilities running application software specificto remote monitoring system 10, or a general purpose computing devicesuch as a personal computer or cellular device capable of running ageneral purpose web browser that accesses information archived at datastorage server 18. EUI 20 can, for example, be a personal computer or awireless tablet or cellular device running an appropriate task-specificsoftware application. EUI 20 has graphical user interface (GUI) 30,which provides end users with a range of aggregated, historical, andreal-time data about fluid handling system 12, as described in greaterdetail below. Although GUI 30 is displayed on EUI 20, the informationdisplayed in GUI 30 can be assembled (i.e. by aggregating operationalparameter data form reports, producing metadata, and calculatingsecondary quantities from reported data) either at data storage server18, or at EUI 20. In many embodiments, data storage server 18 and EUI 20can communicate via communication network 16 with a plurality ofcommunications modules 14 attached to fluid handling systems 12. In thisway, EUI 20 enables end users to remotely access aggregated, historical,and real-time data about multiple, geographically distributed fluidhandling devices.

FIG. 2 is a schematic block diagram illustrating logic components ofremote monitoring system 10. As described above, remote monitoringsystem 10 comprises fluid handling system 12, communications module 14,communications network 16, data storage server 18, and EUI 20. Asillustrated in FIG. 2, remote monitoring system 10 further comprisesadditional fluid handling systems 12 a and 12 b connected to additionalcommunications modules 14 a and 14 b, respectively. Fluid handlingsystems 12 a and 12 b can, for example, be additional identical orsimilar fluid handling systems to fluid handling system 12. Fluidhandling systems 12 a and 12 b may differ from each other and from fluidhandling system 12 in specifics of form and function, but are generallyfluid handling systems as described above with respect to FIG. 1. Ingeneral, remote monitoring system 10 can include any number of fluidhandling systems with corresponding communications modules.

In addition to heating and pressurizing fluid (see FIG. 1), fluidhandling system 12 collects, receives, and produces data regarding arange of operational parameters, including actual and commandedtemperatures and pressures, error or event codes and states, and “dutydata” such as device on-time, hours of use, pump cycle counts and otherduty cycle data. In the illustrated embodiment, fluid handling system 12comprises temperature sensors 102 a and 102 b, pressure sensors 104 aand 104 b, subsidiary processor 106, fluid handling processor 100, andlocal transceiver 108. Temperature sensors 102 a and 102 b can, forinstance, be thermocouples, resistive temperature detectors, bimetallicsensors, or other temperature sensors selected for suitability for theoperating conditions of fluid handling system 12. Temperature sensors102 a and 102 b can, for example, be disposed at inlet and/or outletlocations of fluid handling system 12 and/or heater module 26. Pressuresensors 104 a and 104 b can, for example, be piezoelectric or capacitivepressure sensors disposed at inlet and/or outlet locations of fluidhandling system 12 and/or pump module 24. Although only two temperaturesensors 102 a and 102 b and two pressures sensors 104 a and 104 b areshown in FIG. 2, fluid handling system 12 can comprise any number ofpressure and temperatures sensors. In particular, embodiments of fluidhandling system 12 with separate A-side and B-side fluid lines canincorporate separate sets of temperature and pressure sensors for eachfluid line.

Fluid handling processor 100 and sub-processor 106 are logic-capabledevices that receive, retrieve, and/or produce operational parameters offluid handling system 12. Although fluid handling processor 100 isdepicted as a single element, some embodiments of fluid handlingprocessor 100 can constitute a plurality of separate logic processors,each separately in communication with appropriate sensors and with localtransducer 108. In one such embodiment, fluid handling processor 100comprises a motor controller processor dedicated to pump motors of pumpmodule 24, and a heater controller processor dedicated to heater module26. Some embodiments of fluid handling system 12 may includesub-processor 106, an additional logic-capable processor thatcommunicates with local transducer 108 only via fluid handling processor100. For example, fluid handling processor 100 may comprise a motorcontroller processor that, in addition to receiving sensor data andcommanded setpoint pressures related to pump operation, receives andaggregates signals from a heater controller processor.

Fluid handling processor 100 (and, in some embodiments, sub-processor106) receives user inputs specifying setpoint temperatures and pressuresfor fluid handling system 12. These setpoint temperatures and pressuresact as commanded or target values towards which heater module 26 andpump module 24 respectively operate. Fluid handling 100 also generatesand/or gathers (e.g. from sub-processor 106) error and event codescorresponding to events such as malfunctions, overheating events, pumpjams, and the like, and counts pump cycles of pump(s) in pump module 24.In some embodiments, fluid handling processor 100 displays some or allof this operational data on LOT 28, and receives inputs (includingtemperature and pressures setpoints) from LOI 28. Fluid handlingprocessor 100 transmits some or all of this operational data to localtransceiver 108, which transmits the operational data to communicationsmodule 14. Local transceiver 108 can transmit operational dataperiodically, continuously, on demand, or as retrieved/produced by fluidhandling processor 100. This operational data can further includesoftware version numbers or codes identifying versions of softwarecurrently used by fluid handling processor 100, sub processor 106, andthe like.

Communications module 14 is a device attached to, integrated into, orotherwise commonly situated with fluid handling system 12.Communications module 14 comprises communications module processor 110,local transceiver 112, Global Positioning System (GPS) module 114,ambient temperature sensor 116, and remote transducer 118. In someembodiments, communications module 14 may be a modular add-on componentto fluid module 12. In other embodiments, communications module 14 maybe an internal component inside the same housing or structure as fluidhandling system 12. In the depicted embodiment, communications moduleprocessor 110 receives operational data from fluid handling processor100 via local transceivers 108 and 112. For embodiments in whichcommunications module 14 is integrated into fluid handling system 12,transceivers 108 and 112 may be unnecessary.

GPS module 114 is a global positioning device capable of receiving GPSsignals, and thence determining the location of communications module 14(and thereby fluid handling system 12). GPS module 114 can be a GPStransceiver disposed to communicate with GPS satellites and transmit GPSsignals to communication module processor 110 for processing, or alogic-capable GPS transceiver-processor that itself determines thelocation of communications module 14 from received GPS signals. Althoughcommunications module 14 is illustrated with GPS module 114, otherlocation finding systems such as cellular triangulation may equivalentlybe used. GPS module 114 provides communications module 110 with eitherprocessed location data (e.g. latitude and longitude), or withunprocessed location data (e.g. satellite signals used by communicationsmodule 110 to determine latitude and longitude).

Ambient temperature sensor 116 is a temperature sensor disposed to senseenvironmental temperatures at or near communications module 14 and fluidhandling system 12. Extreme temperatures can adversely affect theviscosity, composition, and degradation of fluids processed by fluidhandling system 12. Ambient temperature sensor 116 provides ameasurement of environmental temperatures that can be used to assess therisk of such adverse temperature reactions.

Communications module processor 110 retrieves operational parametersfrom fluid handling processor 100 as described above, GPS locationinformation from GPS module 114, and sensed environmental temperaturesfrom ambient temperature sensor 116. Communications module processor 110aggregates these data to form a data report that includes bothoperational parameter information (e.g. commanded and sensedtemperatures and pressures, pump cycle counts, software version numbers)and location information (e.g. location coordinates based on the GPSlocation information and a temperature at the location from the sensedenvironmental temperature). This data report is transmitted to datastorage server 18 via communication network 16 by remote transceiver118. Remote transceiver 118 can, for instance, be a cellular or otherwireless transceiver capable of transmitting and receiving signals toand from remote locations. Communications module processor 110 canassemble and transmit data reports periodically, continuously orsemi-continuously, or on-demand in response to user requests or fluidhandling system events (e.g. errors or alerts generated by fluidhandling processor 100).

Data storage server 18 receives data reports from communications module14, and parallel, similar reports from any additional communicationsmodules 14 a and 14 b. Additional communications modules 14 a and 14 bcan collect different data set from fluid handling systems 12 a and 12b, respectively, and may accordingly transmit reports that differ fromthe data reports generated by communications module 14.

Data storage server 18 is a persistent data storage medium that canfurther include a logic-capable processor. In the depicted embodiment,data storage server 18 comprises a plurality of interconnected storagedevices 120 a, 120 b, and 120 c. Storage devices 120 a, 120 b, and 120 ccan, for example, be separate drives arranged in a redundant arrayand/or distributed storage devices situated in disparate locations. Moregenerally, data storage server 18 may comprise any number of datastorage devices, including only a single data storage device. Datastorage server 18 receives data reports from all communication modules(14, 14 a, 14 b, etc.) in remote monitoring system 10, and archives bothoperational parameter information and location information for eachfluid handling system (12, 12 a, 12 b, etc.) in remote monitoring system10.

EUI 20 acts as a terminal by which a human operator can accessinformation stored in data storage server 18 using GUI 30. Although onlyone EUI 20 is shown in FIG. 2, some embodiments of remote monitoringsystem 10 may allow a greater number, or any number, of EUls 20. GUI 30provides users with a range of aggregated, historical, and real-timedata about multiple fluid handling systems, accessible from the singlelocation of EUI 20, which may be remote from any fluid handling systems.For example, an employee of a company or project employing many fluidhandling systems (e.g. 12, 12 a, and 12 b) at various locations monitorall of these devices from EUI 20. Moreover, because data storage server18 archives the contents of data reports from each fluid handling system12, 12 a, 12 b for an extended period, EUI 20 enables users to accessand compare historical data including historical sensed and commandedtemperatures and pressures, software version histories, pump cyclecounts, error and event log histories, and past devicelocations/movement. Software version numbers and histories can be usedto identify reading discrepancies between different machines due todifferences in software version. Data storage server 18 can selectivelypurge some or all of this information periodically, e.g. automaticallydeleting data older than a threshold period. EUI 20 may communicate withdata storage device server 18 either directly, or via communicationnetwork 16.

EUI 20 and data storage server 18 cooperate to provide users withreal-time (or substantially real-time) data and historical data, as wellas data derived from real-time and/or historical data. These deriveddata can be produced at EUI 20 using archived data retrieved from datastorage server 18, or locally at data storage server 18, e.g. on demandfrom EUI 20. Derived data available via GUI 30 at EUI 20 can includepumped fluid volumes (per hour, per day, etc.) derived from pump cyclecounts and pumping volumes known for each model and application of fluidhandling system 12. Derived data can also include alerts or alarmsgenerated whenever particular event or error codes are received, and/orwhenever operating parameters deviate sufficiently from expected values.For example, EUI 20 and/or data storage server 18 can automaticallygenerate alerts whenever sensed pressures exceed commanded values bymore than a threshold amount, or whenever sensed temperatures deviatefrom commanded values by more than a threshold amount for a sufficienttime. EUI 20 allows users to access a wide range of data pertaining tomultiple fluid applicator systems from a remote location, using GUI 30.

FIG. 3 is an illustrative view of one embodiment of GUI 30. As shown inFIG. 3, GUI 30 includes information screen 200 with a plurality of rows202 (including rows 202 a and 202 b) with header row 204, and columns206-232 corresponding to particular parameters. Each row 202 correspondsto an individual fluid applicator system comprising a fluid handlingsystem (e.g. 12, 12 a, 12 b) and a communications device (e.g. 14, 14 a,14 b), with column entries for that row representing operationalparameter data, location data, or derived data for that fluid applicatorsystem. Although only one information screen 200 is shown, someembodiments of GUI 30 can include multiple information screens 200 thatcan be displayed simultaneously, or which users can page between toaccess information, e.g., pertaining to different projects or differentfluid applicator system types. Each information screen 200 can bescrollable and/or resizable to change the range and/or scale of rows andcolumns shown.

As depicted in FIG. 3, information screen 200 includes device modelcolumn 206, device status column 208, daily material usage column 210,daily actual spray time column 212, daily power on time column 214,daily cycle count column 216, resettable cycle count column 218, A-sidetemperature column 220, B-side temperature column 222, hose temperaturecolumn 224, A-side pressure column 226, B-side pressure column 228, lastdevice data column 230, and data/location column 232. These columnsrepresent one embodiment of information screen 200; in otherembodiments, additional or fewer parameters can be displayed. In someembodiments, the columns displayed on information screen 200 can beconfigurable by end users.

In the depicted embodiment, device model column 206 displays theparticular make or model of each fluid applicator system represented inrows 202. EUI 20 and/or data storage server 18 can associate each makeor model with particular fluid tasks, and/or with known pumpdisplacement values. Status column 208 provides indicators of devicestatus for each fluid applicator system in the form of a colored icon orgraphic. Status column 208 can, for instance, show a green circle for apresently active (i.e. heating and/or pumping) fluid applicator system,a yellow circle for an applicator system that was recently active, and ared circle for an applicator for a system that has not been active forsome time (e.g. >10 minutes). In some embodiments, status column 208 caninclude color or text indicators of alarm conditions or urgent events.In alternative embodiments, other types of indicators may be used. Dailymaterial usage column 210 represents fluid volume pumped by each fluidapplicator system, as calculated from cycle counts and known pumpdisplacement volumes for each device model. Daily actual spray timecolumn 212, daily power on time column 214, and daily cycle count column216 represent corresponding duty parameters determined from archivedprocess parameter data included in the data reports, and resettablecycle count column 218 represents a count of pump cycles since manuallyreset by a user at EUI 20 or LOI 28. These daily value columnscorrespond to aggregated historical values based on archived datareports across an extended time period. Although these columns are shownand described herein as fields corresponding to daily values, other timeperiods can be used as appropriate to each application, e.g. hourly,weekly, monthly, etc.

A-side temperature column 220, B-side temperature column 222, hosetemperature column 224, A-side pressure column 226, and B-side pressurecolumn 228 represent temperatures and pressures taken from the mostrecent data reports from each fluid applicator system. A-side and B-sidetemperature columns 220 and 222 can, for example, represent inlet oroutlet fluid temperatures at respective sides of each fluid applicatorsystem, while hose temperature column 224 can represent temperatures atthe hose-end spray/application location of each fluid applicator system.Last device data column 230 indicates the last time at which a datareport was received from each fluid applicator system.

Data and location column 232 provides a plurality of additional databuttons, including job log button 234, daily usage log button 236, eventlog button 238, and location button 240. Each button calls up additionaldetailed historical data when clicked, e.g. in a popup or drop-downwindow. Job log button 234 calls up a history of temperatures,pressures, cycle counts, and other operational parameters from datastorage server 18. Daily usage button 236 calls up a history by day (inthe exemplary embodiment) of usage statistics, e.g. corresponding tocolumns 210, 212, 214, and 216. Event log button 238 calls up a historyof event and/or error codes. Location button 240 calls up a history oflocations based on GPS location data, indicating where a fluidapplicator system has been, and when it has moved. The historical dataaccessed via buttons 234, 236, 238, and 240 can span the full archivedhistory available from data storage server 18, or only recent events(e.g. the last month, year, etc.).

Each row 202 further includes an expand/contract button 242 that expandsthat row to display additional details 244 (see rows 202 a and 202 b).Additional details 244 may, for example, include device addressinformation, ambient temperature, and last update times for particularinformation, e.g. GPS location, ambient temperature, and/or inlettemperatures. Additional details 244 include data retrieved and archivedin data storage server 18 but not otherwise shown in columns 206-232.

GUI 30 enables users to assess the current status and historicalperformance of multiple devices at a glance, from a remote centrallocation. GUI 30 may, in some embodiments, be customizable to allow eachuser to immediately view the information most relevant to his or her owntask. In an exemplary embodiment, GUI 30 may be customizable to hide orshow particular fields by clicking an icon or graphic such as button242. In further or alternative embodiments, GUI 30 may be customizableto hide or show particular fields by editing a configuration file.

FIG. 4 is a method flowchart of method 300, an illustrative embodimentof one method of operating remote monitoring system 10. Although method300 illustrates steps performed in one illustrative order, alternativeembodiments of the present invention may perform steps of method 300 indifferent orders, without departure from the present invention.

First, fluid handling system processor 100 retrieves or produces avariety of parameters, as described above. In the depicted embodiment,fluid handling system processor 100 reads an A-side temperature fromtemperature sensor 102 a (Step S1), an A-side pressure from pressuresensor 104 a (Step S2), a B-side temperature from temperature sensor 102b (Step S3), and a B-side pressure from pressure sensor 104 b (Step S4),either directly or via a subsidiary processor such as sub-processor 106.Fluid handling system processor 100 receives temperature and pressureset points corresponding to A-side and B-side commanded temperatures andpressures (Step S5), and pump cycle counts (Step S6). All of theseoperational parameters are assembled into a fluid handling data packet(Step S7) that is retrieved by communications module processor 110 vialocal transceivers 108 and 112. (Step S8). The fluid handling datapacket can additionally contain other information, as described abovewith respect to FIG. 2, such as error and/or event codes, and softwareversions.

Communications module processor 110 reads a GPS location from GPS module114 (Step S9), reads an environmental temperature from ambienttemperature sensor 116 (Step S10), and assembles a data reportcomprising a composite data packet including the contents of the fluidhandling data packet, the GPS location, and the environmentaltemperature (Step S11). In some cases or embodiments, communicationsmodule processor 110 may assemble some data reports without the GPSlocation and/or the environmental temperature, providing thisinformation less frequently, or on demand. Communications moduleprocessor 110 transmits the data report through communications network16 via remote transceiver 118 to data storage server 18, (Step S12)where all of the contained data is archived (Step S13). EUI 20 and/ordata storage server 18 aggregates data across multiple packets fromdisparate devices, assembling historical and derived data. (Step S14).GUI 30 of EUI 20 is then updated with this information. (Step S15).Method 300 repeats at each iteration of data collection, for each fluidapplicator system, although some data collection steps of method 300 maybe skipped in some iterations (e.g. reading GPS locations). Method 300may automatically repeat at fixed intervals and/or on demand.

Method 300 ensures that GUI 30 provides users with substantiallyup-to-date information about a plurality of fluid applicator systems.This information includes not only real-time or quasi-real-timeoperational parameter data such as commanded and actual temperature andpressure readings, but also historical data including usage statisticsfor the past days or months of operation, and derived data such asmaterial usage statistics.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments ofthe present invention.

A remote monitoring system comprises a fluid handling system and acommunications module. The fluid handling system comprises: a fluiddelivery subsystem configured to pump and heat a fluid; at least onetemperature sensor disposed on the fluid delivery subsystem to sensetemperatures of the fluid; at least one pressure sensor disposed on thefluid delivery subsystem to sense pressures of the fluid; and a fluidhandling system processor configured to produce duty data and commandedpressures and temperatures for the fluid delivery subsystem, andconfigured to receive the sensed pressures and temperatures. Thecommunications module is attached to the fluid handling system, andcomprises: a communications module processor configured to retrieve afirst data set comprising the duty data, the commanded pressures andtemperatures, and the sensed pressures and temperatures, and to producea second data set that includes the first data set; and a transceiverdisposed to transmit the second data set via a communication network toan end user-accessible data storage server.

The remote monitoring system of the preceding paragraph can optionallyinclude, additionally and/or alternatively, any one or more of thefollowing features, configurations and/or additional components:

A further embodiment of the foregoing remote monitoring system, whereinthe communications module further comprises: a global positioning system(GPS) unit configured to identify a location of the communicationsmodule, and thereby the fluid handling system; and wherein the seconddata set further comprises the location of the communications module.

A further embodiment of the foregoing remote monitoring system, whereinthe communications module further comprises: an ambient temperaturesensor configured to sense an environmental temperature at thecommunications module; and wherein the second data set further comprisesthe sensed environmental temperature.

A further embodiment of the foregoing remote monitoring system, whereinthe duty data includes a pump cycle count, and wherein the second dataset comprises a pumped volume determined from the pump cycle count.

A further embodiment of the foregoing remote monitoring system, whereinthe commanded pressures and temperatures are pressure and temperaturesetpoints of the fluid delivery subsystem, and wherein the fluidhandling processor controls the fluid handling subsystem according tothe pressure and temperature setpoints.

A further embodiment of the foregoing remote monitoring system, whereinthe fluid handling processor comprises a motor controller processor unitand a heater controller processor unit.

A further embodiment of the foregoing remote monitoring system, whereinthe at least one temperature sensor comprises a temperature sensordisposed at a fluid inlet of the fluid handling system, and atemperature sensor disposed at a fluid outlet of the fluid handlingsystem.

A further embodiment of the foregoing remote monitoring system, whereinthe second data set further comprises event codes indicating events anderrors experienced by the fluid handling system and/or thecommunications module.

A further embodiment of the foregoing remote monitoring system, whereinthe transceiver transmits the second data set wirelessly via a cellularnetwork.

A further embodiment of the foregoing remote monitoring system, whereinthe fluid handling system is a dual fluid system with an A-side fluidsystem comprising an A-side pump and an A-side heater, and a B-sidefluid system comprising a B-side pump and a B-side heater.

A further embodiment of the foregoing remote monitoring system, whereinthe sensed temperatures, sensed pressures, commanded temperatures, andcommanded pressures comprise temperatures and temperatures of both theA-side fluid system and the B-side fluid system.

A remote monitoring system for a fluid applicator system disposed toheat and pump spray fluid, and to transmit reports via a network, theremote monitoring system comprising a data storage server and an enduser interface. The data storage server is configured to retrieve andarchive the reports, including sensed temperatures and pressures of thefluid applicator system. The end user interface is configured to providea graphical user interface based on the reports, the graphical userinterface outputting: a status of the fluid handling system; sensed andcommanded temperatures of the fluid handling system; sensed andcommanded pressures of the fluid handling system; and usage statisticsof the fluid handling system.

A remote monitoring system for a fluid applicator system disposed toheat and pump spray fluid, and to transmit reports including sensedtemperatures, pressures, and other operational parameters of the fluidapplicator system via a wireless network, the remote monitoring systemcomprising a data storage server and an end user interface configured toprovide a graphical user interface based on the reports. The datastorage server is configured to retrieve and archive the reports. Thegraphical user interface illustrates: a status of the fluid handlingsystem; sensed and commanded temperatures of the fluid handling system;sensed and commanded pressures of the fluid handling system; and usagestatistics of the fluid handling system.

The remote monitoring system of the preceding paragraph can optionallyinclude, additionally and/or alternatively, any one or more of thefollowing features, configurations and/or additional components:

A further embodiment of the foregoing remote monitoring system, whereinthe sensed temperatures included in the reports comprise inlet andoutlet fluid temperatures of the fluid applicator system.

A further embodiment of the foregoing remote monitoring system, whereinthe sensed pressures included in the reports comprise inlet and outletpressures of the fluid handling system.

A further embodiment of the foregoing remote monitoring system, whereinthe fluid applicator system comprises a pump and a heater, and whereinthe other operational parameters included commanded pressures andcommanded temperatures of the pump and the heater, respectively.

A further embodiment of the foregoing remote monitoring system, whereinthe fluid applicator system is a dual fluid system with an A-side fluidsystem comprising an A-side pump and an A-side heater, and a B-sidefluid system comprising a B-side pump and a B-side heater.

A further embodiment of the foregoing remote monitoring system, whereinthe other operational parameters include usage statistics comprisingfluid handling system on-time, pumping time, and pumped volume based onpump duty cycles.

A further embodiment of the foregoing remote monitoring system, whereinthe graphical user interface provides a history of temperatures,pressures, and usage statistics from the archived reports.

A further embodiment of the foregoing remote monitoring system, whereinthe graphical user interface provides a history of event logs indicatingerror and event codes reflecting events experienced by the fluidapplicator system.

A further embodiment of the foregoing remote monitoring system, whereinthe graphical user interface provides location information indicating alocation of the fluid handling system, based on global positioningsystem data.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

The invention claimed is:
 1. A fluid handling and monitoring system,comprising: a mobile fluid applicator for spraying A- and B-side fluidsof a spray coating or polyurethane foam, including: an A-side fluidsystem having an A-side pump, an A-side heater, an A-side temperaturesensor, and an A-side pressure sensor; a B-side fluid system having aB-side pump, a B-side heater, a B-side temperature sensor, and a B-sidepressure sensor; a local operator interface that displays fluid handlingoperational data including commanded and sensed A- and B-side pressuresand temperatures, wherein the local operator interface receives a firstuser input that specifies the commanded A-side pressure and a seconduser input that specifies the commanded B-side pressure, and the A-sidefluid system pressurizes the A-side fluid to the commanded A-sidepressure, and the B-side fluid system pressurizes the B-side fluid tothe commanded B-side pressure; and a remote communication deviceattached to the mobile fluid applicator and including cellular networktransceiver that wirelessly transmits a remote monitoring data setincluding at least the commanded and sensed A- and B-side pressures andtemperatures; a mobile fluid applicator housing, the local operatorinterface, the A-side pump, the B-side pump, and the remotecommunication device each located at least partially within the mobilefluid applicator housing; and a remote end user interface including acellular device that displays at least the commanded and sensed A- andB-side pressures and temperatures in a single graphical user interfacesuch that the commanded and sensed A-and B-side pressures andtemperatures are simultaneously viewable on the remote end userinterface contemporaneously with the local operator interface alsodisplaying the commanded and sensed A- and B-side pressures andtemperatures of the fluid handling operational data in a singlegraphical user interface such that the commanded and sensed A- andB-side pressures and temperatures are simultaneously viewable on thelocal operator interface; wherein the mobile fluid applicator housing iswithin a mobile vehicle, the local operator interface, the A-side pump,A-side heater, B-side pump, and B-side heater located entirely withinthe mobile vehicle.
 2. The system of claim 1, wherein the remote enduser interface is remote from the mobile fluid applicator housing. 3.The system of claim 2, wherein the remote end user interface includes agraphic user interface on the cellular device displaying real-time dataabout the mobile fluid applicator.
 4. The system of claim 2, wherein theremote monitoring data set wirelessly transmitted by the cellularnetwork transceiver includes an operational status of the mobile fluidapplicator.
 5. The system of claim 4, wherein the remote end userinterface displays contemporaneously with the local operator interfacethe operational status and the commanded and sensed A- and B-sidepressures and temperatures.
 6. The system of claim 5, wherein the remotemonitoring data set wirelessly transmitted by the cellular networktransceiver further includes duty cycle data, and wherein the remote enduser interface displays contemporaneously with the local operatorinterface the duty cycle data, the operational status, and the commandedand sensed A- and B-side pressures and temperatures.
 7. The system ofclaim 6, wherein the operational status is displayed by a coloredindicator indicative that the system is heating.
 8. The system of claim6, wherein the operational status is displayed by a colored indicatorindicative that the system is heating and not pumping.
 9. The system ofclaim 6, wherein the operational status is displayed by a coloredindicator indicative that the system is heating and pumping.
 10. Thesystem of claim 5, wherein the remote monitoring data set wirelesslytransmitted by the cellular network transceiver further includes anerror status of the mobile fluid applicator.
 11. The system of claim 5,wherein the remote monitoring data set wirelessly transmitted by thecellular network transceiver further includes an ambient temperaturedetermined based on an ambient temperature sensor located proximate themobile fluid applicator housing.
 12. The system of claim 5, wherein theremote end user interface including the cellular device wirelesslyreceives the remote monitoring data set.
 13. The system of claim 5,further comprising a second remote end user interface that displays atleast the commanded and sensed A- and B-side pressures and temperaturescontemporaneously with the local operator interface displaying thecommanded and sensed A- and B-side pressures and temperatures.
 14. Thesystem of claim 13, wherein the second remote end user interfacedisplays contemporaneously with the local operator interface theoperational status and the commanded and sensed A- and B-side pressuresand temperatures.
 15. The system of claim 13, wherein the local operatorinterface is visible by a user externally from the mobile fluidapplicator housing to view the fluid handling operational data includingcommanded and sensed A- and B-side pressures and temperatures.
 16. Thesystem of claim 1, comprising an A-fluid hose that extends between theA-fluid pump located within the mobile vehicle to an applicator, and aB-fluid hose that extends between the B-fluid pump located within themobile vehicle to the applicator.
 17. The system of claim 1, comprisinga fluid applicator processor and an error threshold, wherein the fluidapplicator processor detects an error event based on a sensed pressurethat deviates from the A-side commanded pressure or the B-side commandedpressure by more than the error threshold.